RANGER 400

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PMS 419RANGER 400Owner's Manualfor Maintenance and Safety

WARNINGRead, understand, and follow all of the instructions and safety precautions inthis manual and on all product labels.Failure to follow the safety precautions could result in serious injury or death.WARNINGThe engine exhaust from this product contains chemicals known to the Stateof California to cause cancer, birth defects or other reproductive harm.

WELCOMEThank you for purchasing a POLARIS vehicle, and welcome to our world-wide family ofPOLARIS owners. We proudly produce an exciting line of utility and recreational products. Snowmobiles All-terrain vehicles (ATVs) RANGER utility vehicles Victory Motorcycles Low Emission Vehicles (LEVs)We believe POLARIS sets a standard of excellence for all utility and recreational vehiclesmanufactured in the world today. Many years of experience have gone into the engineering,design, and development of your POLARIS vehicle, making it the finest machine we’ve everproduced.For safe and enjoyable operation of your vehicle, be sure to follow the instructions and recommendations in this owner’s manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the POLARIS Service Manual andshould be performed only by a factory certified Master Service Dealer (MSD) technician.Your POLARIS dealer knows your vehicle best and is interested in your total satisfaction. Besure to return to your dealership for all of your service needs during, and after, the warrantyperiod.We also take great pride in our complete line of apparel, parts and accessories, availablethrough our online store at www.purepolaris.com. Have your accessories and clothing delivered right to your door!1

POLARIS, THE WAY OUT and RANGER are registered trademarks of POLARIS Industries Inc.Copyright 2011 POLARIS Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of productioncomponents, some minor discrepancies may result between the actual vehicle and the information presented inthis publication. Depictions and/or procedures in this publication are intended for reference use only. No liabilitycan be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.The original instructions for this vehicle are in English. Other languages are provided as translations of the original instructions.Printed in U.S.A.2012 RANGER 400 Owner’s ManualP/N 99235092

TABLE OF CONTENTSIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Features and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Emission Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38POLARIS Products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 853

INTRODUCTIONThe RANGER is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area.The following signal words and symbols appear throughout this manual and on your vehicle.Your safety is involved when these words and symbols are used. Become familiar with theirmeanings before reading the manual.The safety alert symbol indicates a potential personal injury hazard.WARNINGA WARNING indicates a hazardous situation which, if not avoided, may result in death or serious injury.CAUTIONA CAUTION indicates a hazardous situation which, if not avoided, may result in minor or moderateinjury.NOTICEA NOTICE indicates a situation that may result in property damage.The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard.The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard.WARNINGFailure to follow the warnings contained in this manual can result in severe injury or death.A POLARIS RANGER is not a toy and can be hazardous to operate. This vehicle handles differentlythan other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even duringroutine maneuvers like turning, or driving on hills or over obstacles, if you fail to take properprecautions. Read this owner’s manual. Understand all safety warnings, precautions and operating proceduresbefore operating the vehicle. Keep this manual with the vehicle. This vehicle is an ADULT VEHICLE ONLY. NEVER operate this vehicle if you are under age 16 andNEVER operate without a valid driver’s license. No person under the age of 12 may ride as a passenger in this vehicle. Any passenger must be ableto comfortably reach the floor and hand holds. Never permit a guest to operate this vehicle unless the guest has read this manual and all productlabels. Always use the cab nets while riding in this vehicle. Always keep hands and feet inside the vehicle at all times.4

INTRODUCTIONVehicle Identification NumbersRecord your vehicle's identification numbers and key number in the spaces provided.Remove the spare key and store it in a safe place. An ignition key can be duplicated only byordering a POLARIS key blank (using your key number) and mating it with one of yourexisting keys. The ignition switch must be replaced if all keys are lost.####KeyNumberVINVehicle Model Number:Frame VIN:Engine Serial Number:(label on side of engine)Key Number:European Vibration and NoiseThe driver-perceived noise and hand/arm and whole body vibration levels of this machineryis measured per prEN 15997.The operating conditions of the machinery during testing:The vehicles were in like-new condition. The environment was controlled as indicated by thetest procedure(s).The uncertainty of vibration exposure measurement is dependent on many factors, including: Instrument and calibration uncertainty Variations in the machine such as wear of components Variation of machine operators such as experience or physique Ability of the worker to reproduce typical work during measurements Environmental factors such as ambient noise or temperature5

SAFETYSafety Labels and LocationsWarning labels have been placed on the vehicle for your protection. Read and follow theinstructions of the labels on the vehicle carefully. If any of the labels depicted in this manualdiffer from the labels on your vehicle, always read and follow the instructions of the labelson the vehicle.If any label becomes illegible or comes off, contact your POLARIS dealer to purchase areplacement. Replacement safety labels are provided by POLARIS at no charge. The partnumber is printed on the label.Passenger/Tire Pressure WarningWARNING Passengers can be thrown off. This can cause serious injury ordeath. Never carry passengers in cargo box. WARNINGIMPROPER TIRE PRESSURE OR OVERLOADING CANCAUSE LOSS OF CONTROL RESULTING IN SERIOUSINJURY OR DEATH. Reduce speed and allow greater distance for braking whencarrying cargo. Overloading or carrying tall, off-center, or unsecured loads willincrease your risk of losing control. Loads should be centeredand carried as low as possible in box. For stability on rough or hilly terrain, reduce speed and cargo. Be careful if load extends over the side of the box.RANGERMAXIMUM CARGO BOX LOADTIRE PRESSURE IN PSI (KPa)4x4CrewLSV-EV500 lbs.(226 kg)FRONT 10 (69)REAR 12 (83)1000 lbs.(454 kg)500 lbs.(226 kg)FRONT 14 (97)REAR 16 (110)1250 lbs.(547 kg)500 lbs.(226 kg)FRONT 20 (138)REAR 20 (138)1000 lbs.(454 kg)MAXIMUM WEIGHT CAPACITYINCLUDES WEIGHT OFOPERATOR, PASSENGER, CARGOAND ACCESSORIESRead Operation and Maintenance Manual for more detailed loading information.7177690Clutch Cover WarningWARNING Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed. Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM whichcan result in serious injury or death.71754886Clutch CoverWarning

SAFETYSafety Labels and LocationsAge 16 WarningOperating this vehicle if you are under the age of 16increases your chance of severe injury or death.NEVER operate this vehicle if you are under age 16 andNEVER operate this vehicle without a valid driver’s license.7175566Age 16WarningDiscretionaryWarningShift CautionShift CautionCAUTIONTo avoid transmission damage, shift only when vehicle isstationary and at idle.APPLY BRAKE TO START. When this vehicle is not inoperation, or unattended, place shift in the park position.7176170Discretionary WarningWARNINGImproper vehicle use can result in Severe Injury or Death.NEVER Operate: At speeds too fast for your skills or the conditions. After or while using Alcohol or Drugs. On hills steeper than 15 degrees15 . On public roads, a collision can occur with a another vehicle. With more than ONE passenger, or a passenger under age twelve or who cannot comfortably reachthe floor and hand holds. On paved surfaces - pavement may seriously affect handling and control. With non-POLARIS approved accessories - they may seriously affect stability.ALWAYS: Wear your seat belt. Vehicle rollover could cause severe injury or death. Wear a helmet and eye protection and keep hands and feet in vehicle at all times. Reduce speed and use extra caution when carrying a passenger. Avoid sharp turns or turns while applying heavy throttle. Operate slowly in reverse - avoid sharp turns or sudden braking. Make sure passenger reads and understands all safety labels. Watch for branches or other hazards that could enter vehicle.LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.71761697

SAFETYSafe Riding GearAlways wear appropriate clothing when riding a POLARIS vehicle. Wear protective clothingfor comfort and to reduce the chance of injury.HelmetWearing a helmet can prevent a severe head injury. Whenever riding this POLARIS vehicle,always wear a helmet that meets or exceeds established safety standards.Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT)label.Approved helmets in Europe, Asia and Oceania bear the ECE 22.05label. The ECE mark consists of a circle surrounding the letter E, folE4lowed by the distinguishing number of the country which has granted051039approval. The approval number and serial number will also be displayed0006.31on the label.Eye ProtectionDo not depend on eyeglasses or sunglasses for eye protection. Whenever riding a POLARISvehicle, always wear shatterproof goggles or use a shatterproof helmet face shield.POLARIS recommends wearing approved Personal Protective Equipment (PPE) bearingmarkings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.GlovesWear gloves for comfort and for protection from sun, cold weather and other elements.BootsWear sturdy footwear. Do not ride a POLARIS vehicle with bare feet.ClothingWear long sleeves and long pants to protect arms and legs.8

SAFETYOperator SafetyWARNINGSerious injury or death can result if you do not follow these instructions and procedures, which areoutlined in further detail within your owner's manual. Read this manual and all labels carefully. Follow the operating procedures described. Never allow anyone under age 16 to operate this vehicle and never allow anyone without avalid driver's license to operate this vehicle. Do not carry a passenger until you have at least two hours of driving experience with thisvehicle. No person under the age of 12 may ride as a passenger in this vehicle. Any passenger mustbe able to comfortably reach the floor and hand holds. The driver and any passenger must wear helmet, eye protection and seat belt at all times.All riders should also wear long sleeves, long pants and sturdy footwear. Always use the cab nets while riding in this vehicle. Always keep hands and feet inside the vehicle at all times. Always keep both hands on the steering wheel and both feet on the floorboards of thevehicle during operation. Never permit a guest to operate this vehicle unless the guest has read this manual and allproduct labels. To reduce tipover risk, be especially careful when encountering obstacles and slopes andwhen braking on hills or during turns. This vehicle is for off road use only. Never operate on public roads. Always avoid pavedsurfaces. Never consume alcohol or drugs before or while operating this vehicle. Never operate at excessive speeds. Always travel at a speed proper for the terrain,visibility and operating conditions, and your experience. Never attempt jumps or other stunts. Always inspect your vehicle each time you use it to make sure it's in safe operatingcondition. Always follow the inspection and maintenance procedures and schedulesdescribed in this manual. Always travel slowly and use extra caution when operating on unfamiliar terrain. Be alertto changing terrain. Never operate on excessively rough, slippery or loose terrain. Always follow proper procedures for turning. Practice turning at slow speeds beforeattempting to turn at faster speeds. Never turn at excessive speeds.9

SAFETYOperator Safety Always have this vehicle checked by an authorized POLARIS dealer if it has beeninvolved in an accident. Never operate this vehicle on hills too steep for the vehicle or for your abilities. Practiceon smaller hills before attempting larger hills. Always follow proper procedures for climbing hills as described in this manual. Check theterrain carefully before attempting to climb a hill. Never climb hills with excessively slippery or loose surfaces. Never open the throttle suddenly or make sudden gear changes.Never go over the top of a hill at high speed. Always follow the proper procedures outlined in this manual for traveling downhill andfor braking on hills. Check the terrain carefully before descending a hill. Never traveldownhill at high speed. Avoid going downhill at an angle, which would cause the vehicleto lean sharply to one side. Travel straight down the hill where possible. Always check for obstacles before operating in a new area. Never attempt to operate overlarge obstacles such as rocks or fallen trees. Always follow the proper procedures outlinedin this manual when operating over obstacles. Always be careful of skidding or sliding. On slippery surfaces such as ice, travel slowlyand exercise caution to reduce the chance of skidding or sliding out of control. Never operate your vehicle in fast-flowing water or in water deeper than that specified inthis manual. Wet brakes may have reduced stopping ability. Test your brakes after leavingwater. If necessary, apply them lightly several times to let friction dry out the pads. Always be sure there are no obstacles or people behind your vehicle when operating inreverse. When it's safe to proceed in reverse, move slowly. Avoid turning at sharp anglesin reverse. Always use the proper size and type of tires specified in this manual. Always maintainproper tire pressure as specified on safety labels. Never modify this vehicle through improper installation or use of accessories. Never exceed the stated load capacity for this vehicle. Cargo should be properly distributed and securely attached. Reduce speed and follow the instructions in this manual forhauling cargo or pulling a trailer. Allow a greater distance for braking. Always place the transmission in PARK before getting out of the vehicle. Always stop the engine before refueling. Make sure the refueling area is well ventilatedand free of any source of flame or sparks. Gasoline is extremely flammable. See page 13for fuel safety warnings. Always remove the ignition key when the vehicle is not in use to prevent unauthorized useor accidental starting.FOR MORE INFORMATION ABOUT SAFETY, callPOLARIS at 1-800-342-3764.10

SAFETYOperator SafetyEquipment ModificationsWe strongly recommend that consumers do not install on a POLARIS RANGER any equipment that may increase the speed or power of the vehicle, or make any other modifications tothe vehicle for these purposes. Any modifications to the original equipment of the vehiclecreate a substantial safety hazard and increase the risk of bodily injury.The warranty on your POLARIS RANGER is terminated if any equipment has been added tothe vehicle, or if any modifications have been made to the vehicle, that increase its speed orpower.The addition of certain accessories, including (but not limited to) mowers, blades, tires,sprayers, or large racks, may change the handling characteristics of the vehicle. Use onlyPOLARIS-approved accessories, and familiarize yourself with their function and effect onthe vehicle.11

SAFETYOperator SafetyWARNINGFailure to operate the RANGER properly can result in a collision, loss of control, accident or overturn,which may result in serious injury or death. Heed all safety warnings outlined in this section of theowner’s manual. See the OPERATION section of the owner’s manual for proper operating procedures.Age RestrictionsThis vehicle is an ADULT VEHICLE ONLY. NEVER operate this vehicle ifyou are under age 16 and NEVER operate without a valid driver’slicense.No person under the age of 12 may ride as a passenger in this vehicle.Any passenger must be able to comfortably reach the floor and handholds.Operating Without InstructionOperating this vehicle without proper instruction increases the risk of anaccident. The operator must understand how to operate the vehicleproperly in different situations and on different types of terrain.All operators must read and understand the Owner's Manual and allwarning and instruction labels before operating the vehicle.Using Alcohol or DrugsOperating the vehicle after consuming alcohol or drugs could adverselyaffect operator judgment, reaction time, balance and perception.Never drink alcohol or use drugs or medications before or whileoperating this vehicle.Seat BeltsRiding in this vehicle without wearing the seat belt increases the risk ofserious injury in the event of an accident or sudden stop. Riders mustwear seat belts at all times. Always make sure the seat belts are securedfor both the operator and passenger before riding.Protective ApparelRiding in this vehicle without wearing an approved helmet and protective eyewear increases the risk ofa serious injuries in the event of an accident.Operator and all passengers must always wear an approved helmet that fits properly and eyeprotection (goggles or face shield).12

SAFETYOperator SafetyCab NetsRiding in this vehicle without using the cab nets increases the risk of serious injury or death in the eventof an accident or overturn. Always use the cab nets while riding in this vehicle.Always keep hands and feet inside the vehicle at all times.Failure to Inspect Before OperatingFailure to inspect and verify that the vehicle is in safe operating condition before operating increasesthe risk of an accident.Always inspect your RANGER before each use to make sure it's in safe operating condition. Alwaysfollow all inspection and maintenance procedures and schedules described in the owner's manual.Handling GasolineGasoline is highly flammable and explosive under certain con

A POLARIS RANGER is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motor cycles and cars. A collision or roll over can occur quickly, even during . before operating the vehicle. Keep this manual with the vehicle. This vehicle is an ADULT VEHICLE ONLY. NEVER operate this vehicle if .

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